EV Charging Case Study:
Gul-e Nylon Brush Test
Overview
AVi provide a wide range of product qualification testing solutions across various sectors. We offer consistent, rigorous, and repeatable testing, critical for products that need to perform well in various environmental conditions.
ODS is responsible for maintaining Oxford City Council’s housing stock, parks, and streets. ODS are committed to finding innovative ways to deliver services that bring genuine benefits to the economy and planet. All of their profits are reinvested into Oxford City Council to protect and enhance essential public services, something AVi are incredibly proud to support.
ODS embrace opportunities to collaborate with local partners who share the same values. This includes supporting the local economy by buying goods and services from purposeful local organisations whenever possible. So, we were delighted to be selected to work with them on their Gul-e project.
Challenge
Between 2023-2024, AVi conducted a series of tests on behalf of ODS for their new innovative Gul-e project. Gul-e is a safe, simple cross-pavement device designed to hold EV charging cables – ideal for households who need to charge an electric vehicle but have no driveway.
The device’s nylon brush inserts needed to be tested for safety and durability against a number of environmental factors. Accelerated life testing was required to simulate what would be thousands of usage cycles over a 5-year period, condensing this into just a few hours.
What we delivered
AVi designed and built hardware and software for the creation of a bespoke automated test system to carry out empirical testing of the Gul-e device.
The initial process started with testing the Gul-e’s performance at an ambient temperature of approx. 22°C. Environmental testing of the cross-pavement device was then completed in an environmental chamber, where temperature conditions could be set to a wide range starting from lows of -60°C and highs of +50°C.
The automated test equipment (A.T.E.) was assembled in the chamber and endurance tests were carried out at high (+45°C) and low (-10°C) temperatures. The computer software controlling the test system was stationed outside of the chamber and hard wired via a hole in the wall.
For each temperature simulation test, an EV cable was attached to the test equipment via a pair of motorised actuator arms. The arms cyclically inserted and removed the cable from the nylon brushes.
The testing simulated a person inserting and removing the EV charging cable from the Gul-e device, just as they would when connecting it to their EV vehicle to charge.
The high and low temperature tests were performed for approximately 3,700 individual motions, totalling approximately 1,850 cycles. With one cycle equal to the cable being lowered in and out of the Gul-e device. This simulated thousands of usage cycles over a 5-year period, in only several hours of testing. This was doubled for a 10-year period.
The result
The condition of the nylon brushes was carefully examined after each temperature cycle. AVi produced comprehensive reports that included data analysis, observations, photos, and video documentation.
Outcome
The test results enabled ODS to ascertain maintenance schedules and also make their assumptions in terms of product warranty periods.
Visit www.gul-e.co.uk for more information about Gul-e by ODS. No driveway? No problem!
